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Barber-Colman Integrated Actuator for Stanadyne "D" Series Injection Pump — Model DYNA 70025

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Barber-Colman Integrated Actuator for Stanadyne DYNA Application Information Power Controls Barber-Colman Integrated Actuator for Stanadyne "D" Series Injection Pump — Model DYNA 70025 Installation Procedure Electric Shutoff Fuel Return Line Solenoid Wire Cover Screws (3) Return Line Connector Assembly Governor Control Cover Figure 1 STEP I REMOVAL OF EXISTING GOVERNOR CONTROL COVER 1.1 Remove the RETURN LINE CONNECTOR ASSEMBLY from the GOVERNOR CONTROL COVER using care not to allow dirt to enter the injection pump. — NOTE — Remove and discard the RETURN LINE CONNEC- Clean outside of pump with solvent and dry with TOR O-RING. Set aside the RETURN LINE CON- compressed air prior to removing the GOVERNOR NECTOR for later installation on the new INTE- CONTROL COVER. A suitable container should be GRATED ACTUATOR COVER ASSEMBLY. placed underneath the fuel injection pump to catch any fuel that may spill when removing the 1.2 Remove the ELECTRIC SHUTOFF (ESO) GOVERNOR CONTROL COVER. SOLENOID WIRE from the GOVERNOR CON- TROL COVER. Trace the solenoid wire back to its 1.0 Remove the FUEL RETURN LINE from the source. Remove and discard the wire. pump's RETURN LINE CONNECTOR ASSEMBLY. Use two wrenches to loosen. See Figure 1. CAUTION Do not use this wire to power the new INTEGRATED ACTUATOR. 1.3 Loosen the three COVER SCREWS and remove the GOVERNOR CONTROL COVER ASSEMBLY from the pump. Save all three screws for later installation of the INTEGRATED ACTUATOR COVER ASSEMBLY. DYNA 105-2 STEP 2 NSTALLING THE EW NTEGRATED Integrated Actuator I N I Cover Assembly ACTUATOR COVER ASSEMBLY 2.0 Install new COVER SEAL — Item 2 from the parts list, into the groove of the INTEGRATED ACTUATOR COVER AS- SEMBLY as shown in Figure 2. 2.1 Align and hold the METERING VALVE DRIVE COUPLING parallel to the side of the INTEGRATED ACTUATOR COVER as shown in Figure 3. Cover Seal 2.2 Position the INTEGRATED ACTUA- TOR COVER ASSEMBLY into the top of the pump while holding the METERING VALVE DRIVE COUPLING parallel to the PUMP BODY. Slightly lift the front portion Figure 2 of the INTEGRATED ACTUATOR COVER as shown in Figure 4. Integrated Actuator Cover 2.3 Carefully slide the INTEGRATED ACTUATOR COVER toward the rear of the pump until the horseshoe portion of the METERING VALVE DRIVE COUPLING contacts the pump's GOVERNOR LINK- AGE HOOK as shown in Figure 5. Once contact has been made, continue moving the INTEGRATED ACTUATOR COVER in the same direction until the mounting holes between the INTEGRATED ACTUATOR COVER and the PUMP BODY are aligned. Metering Valve CAUTION Drive Coupling Failure to properly install the METER- ING VALVE DRIVE COUPLING to the pump's GOVERNOR LINKAGE can result in serious damage. Figure 3 2.4 Obtain three COVER SCREWS re- Integrated Actuator Cover tained from the original GOVERNOR CONTROL COVER. Assemble the INTE- GRATED ACTUATOR COVER to the PUMP BODY with these screws. Tighten screws to 35 - 45 lbs/in. 2.5 Install a new O-RING — Item 3 from the parts list, on the RETURN LINE CON- NECTOR ASSEMBLY retained from the Pump original GOVERNOR CONTROL COVER. Body Apply a light coating of all purpose grease to the O-RING and install connector into the 7/16-20 UNF-2A threaded hole located in the INTEGRATED ACTUATOR COVER. Tighten to 43 - 53 lbs/in. Rear Front See CAUTION following on page 3. Figure 4 2 Integrated CAUTION Actuator Steps 3.0 thru 3.3 are performed Cover PRIOR to starting the engine. Governor Metering Linkage Valve Drive 3.0 Position the SHUT-OFF SHAFT AS- Hook Coupling SEMBLY (if equipped with one) in the "Fuel On" position by rotating it in the Front direction shown in Figure 6 until it reaches its limit of travel. Secure the SHUT-OFF Rear SHAFT ASSEMBLY in place with existing mechanical linkage. A spring may be used to hold it in place when there is no linkage. CAUTION Do not attach springs to the engine's high pressure lines. Figure 5 3.1 THROTTLE SHAFT ASSEMBLIES are often locked in the "High Idle" position CAUTION on pumps equipped with speed droop If the RETURN LINE CONNECTOR is a 7/16-20 UNF-2A, governors. When this is the case, the paragraph 2.5 can be completed. If the RETURN LINE LOW IDLE SCREW may be backed out a CONNECTOR is not 7/16-20 UNF-2A, there are two maximum of three (3) turns. This should possible solutions: only be done if the HIGH IDLE speed is known to be greater than 12% above the OPTION 1 rated speed. Excessive backing out of A Stanadyne 21251 RETURN LINE CONNECTOR may the LOW IDLE SCREW may result in the be used to replace the RETURN LINE CONNECTOR disengagement of the pump's internal ASSEMBLY on the return fuel line. components. OPTION 2 — WARNING — A Stanadyne 24509 CONNECTOR BODY can be used to This procedure must be followed mate the 1/8-27 NPT RETURN LINE CONNECTOR carefully in order to not overspeed ASSEMBLY to the 7/16-20 UNF-2A threaded hole lo- the engine and cause damage to the cated in the INTEGRATED ACTUATOR COVER. generator or other load. 3.2 Adjust the droop by turning the 2.6 Install the FUEL RETURN LINE to the RETURN LINE DROOP ADJUSTING SCREW in a CONNECTOR. Hold RETURN LINE CONNECTOR in place counterclockwise (CCW) direction until and tighten FUEL RETURN LINE to engine manufacturer's it stops. See Figure 6. Some pumps specification. may not be equipped with a speed droop adjustment. STEP 3 Turn the DROOP ADJUSTING PRELIMINARY SET-UP PROCEDURE SCREW clockwise (CW) two full turns. The mechanical governor is now set in — NOTE — a position that will permit starting the The following method will be used to properly set up the engine to calibrate the ELECTRONIC mechanical governor for operation with the ELECTRONIC INTEGRATED ACTUATOR GOVER- INTEGRATED ACTUATOR. Proper calibration of both the NOR. Do not operate the engine with- mechanical and electronic governor must be performed in out the electronic governor connected order for the system to operate properly. Failure to perform and the system calibrated properly as this procedure properly may result in inability to provide described in Step 6. maximum power or cause poor steady state speed control. Once this droop adjustment has 3 been made, do not readjust. Terminal Strip Fuel Return Integrated Line Port Actuator Cover Maximum Cover Screws (3) Cover Screw Throttle Shaft Assembly Low Idle Screw Pump Body High Idle Adjustment Screw Figure 6 STEP 4 MAGNETIC PICKUP INSTALLATION EXAMPLE: If desired speed is 1800 RPM for electronic governing, then 1800 x 0.12 = 216 RPM; 1800 + 216 = 4.0 Refer to Bulletin Number 2, F-16457-1. 2016 RPM. STEP 6 STEP 5 CALIBRATION PROCEDURE GOVERNOR CONTROL BOX INSTALLATION 6.0 Make certain the electronic governor adjustments CAUTION are set as stated in the proper governor literature. Make certain that proper voltage (12 or 24 Vdc) GOVERNOR CONTROL BOX and INTEGRATED The SPEED adjustment is a 20 turn potentiometer ACTUATOR ASSEMBLY are used. on the DYN1-10784 and DYN1-10794 control boxes. Turn it counterclockwise (CCW) 20 turns and then clock- 5.0 Wire and pre-set the adjustments of the INTE- wise (CW) 5 turns. GRATED GOVERNOR system as described in the wiring and calibration information for the controller's 6.1 Rotate and hold the THROTTLE SHAFT LEVER specific part number. Make certain to use the shielded to maximum position as permitted by present high idle wire and twisted cables as shown in the installation screw adjustment. Do not attempt at this time to adjust information. the high idle screw beyond its present setting. Connect ACTUATOR WIRES to the two center 6.2 Turn on the DC power to the system. terminals on the terminal strip. Do not connect any other wires to the actuator than the ones from the governor — NOTE — control box. Be sure Step 6.0 has been performed. 5.1 The mechanical governor is to be set 12% higher 6.3 Start the engine. The engine should be than the desired running speed. Calculate the maximum operating on the INTEGRATED ACTUATOR speed setting for the mechanical governor as follows: COVER GOVERNOR. The speed should be below 1800 RPM or the desired speed. 4 — NOTE — — NOTE — Check for fuel leaks. On some pump bodies, the LOW IDLE adjustment screw may not be able to position the throttle lever 6.4 Slowly using the GOVERNOR CONTROL to the proper position. If it cannot hold the throttle BOX speed adjustment, increase the engine speed. to the proper position, use a spring to hold the (If the engine does not increase in speed, follow throttle to the maximum position or maximum the troubleshooting procedure in the governor speed and power will not be obtainable. manual) 6.5 Keep increasing the speed until it is approxi- CAUTION mately 20 RPM higher than the speed calculated Do not attach springs to the engine's high in Step 5.1. If this speed cannot be obtained, pressure lines. loosen the jam nut on the HIGH IDLE SPEED ADJUSTMENT SCREW of the THROTTLE LEVER and turn the HIGH IDLE ADJUSTMENT SCREW 6.8 Decrease the speed on the ELECTRONIC counterclockwise (CCW) until the calculated speed GOVERNOR CONTROL BOX until the desired run can be obtained. See Figure 6. speed is obtained. 6.6 Set the speed with the electronic governor to 6.9 Properly calibrate the adjustments of the the value calculated in Step 5.1. Then slowly turn electronic governor. the HIGH IDLE ADJUSTMENT SCREW on the THROTTLE LEVER clockwise (CW) until the speed Check the system for good response and just starts to decrease.
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